Affordable energy efficient and disaster proof residential structures

ABSTRACT

The disclosed technology provides a module useful in constructing an energy efficient, durable building structure, the module including walls to form a vacuous, sealed chamber substantially void of structural elements, materials and gaseous molecules. One or more ribs are affixed to or formed integral with an exterior surface of the exterior wall of the module, extending the width of the module. The disclosed technology further provides a vacuum apparatus which may be incorporated in communication with the vacuous, sealed chamber, for creating and maintaining a vacuum within the module. A method of controlling heat transfer within a structure is also provided, utilizing the modules as herein disclosed, each module being coupled with a vacuum apparatus in communication with the vacuous, sealed chamber, for creating and maintaining a vacuum within the module.

BACKGROUND

The disclosed technology regards affordable, energy efficient, durablebuilding structures and components thereof, including a plurality ofmodules, each module having a vacuous chamber substantially void ofstructural elements, materials and gaseous molecules. The disclosedtechnology further includes an apparatus for creating and maintaining avacuum within the vacuous chamber of a structural module.

Planet Earth is experiencing dramatic environmental changes that arenegatively affecting humanity. The polar ice caps are melting, causingthe oceans to rise and increase in temperature. These changes arecausing a dramatic increase in flooding, droughts, hurricanes,tornadoes, wildfires, etc. Much of the scientific community attributesthis “Global Warming” to a dramatic increase in carbon dioxide in ouratmosphere caused by the excessive burning of fossil fuels. A smallpercentage believe that this is just a natural cycle that will completeitself in due time.

In addition, as the world's population increases so does the world'sneed for residential structures. This increase raises the demand forenergy consumption used in heating and cooling the same. This demand iscompounded by natural disasters, such as hurricanes, tornados, andwildfires, which are destroying residential structures at an alarmingrate. Energy used to deal with heating and cooling of residential andcommercial structures, and for the construction of new structures andreplacement of destroyed structures, represents a significant portion ofthe strain placed upon the environment and our economy.

Ultimately, if we are to survive as a human race we must come up with aplan of action that can practically deal with these problems. A step inthe right direction is the continued search for more energy efficientand storm proof residential and commercial structures.

An understanding of heat transfer is foundational in the development ofenergy efficient and storm proof residential and commercial structures.Thermal energy is transferred by three primary means: conduction,convection and radiation.

Conduction is the transfer of thermal energy through an object by aseries of collisions between adjacent atoms, molecules, or other formsof mass. For example, if the end of a steel rod is placed on a hotplate, the heat will be transferred through the rod until thetemperature of the opposite end of the rod becomes the same as the firstend on the hot plate. Specifically, the energy from the hot plate causesthe molecules in the first end of the steel rod to move faster, whichmolecules transfer some of their extra kinetic energy to neighboringmolecules and these, in turn, affect their neighbors. Therefore, thetemperature of the entire steel rod increases. How rapidly an objecttransfers thermal energy by conductivity depends, in part, on theobject's material.

Convection is the transfer of thermal energy due to the motion of thesubstance (gas or liquid) that contains the thermal energy. Naturalconvection results from the tendency of most fluids to expand whenheated—i.e., to become less dense and to rise as a result of theincreased buoyancy. Circulation caused by this effect accounts for theuniform heating of water in a kettle or air in a heated room: the heatedmolecules expand the space they move in through increased speed againstone another, rise, and then cool and come closer together again, withincrease in density and a resultant sinking.

In radiation (also known as electromagnetic radiation), thermal energycan be transferred from one location to another, even without a medium(e.g., air or water). The thermal energy can pass through a perfectvacuum, as energy from the sun does in reaching Earth. If a personstands near an open fire, the side of her facing the fire becomes muchwarmer than the other side. Most of the energy is transferred from theburning material to the person by means of electromagnetic radiation (aportion of heat energy is also transferred by means of thermalconduction and convection).

For heat energy to be transferred between two points, a temperaturedifferential between those two points must exist. Unless forcedotherwise, heat flows from regions of higher temperature to regions oflower temperature. To transfer thermal energy as heat from a cooler to awarmer region, work is required. It is important to note that heatenergy moved by radiation can be mitigated by using materials to absorbor reflect the energy. For example, different colors, materials andstructures can be used to affect the absorption or reflection of radiantenergy.

Traditionally, heat transfer is mitigated in residential and commercialstructures by insulation used in the structure's walls, ceilings andfloors. An insulating material's resistance to conductive heat flow ismeasured or rated in terms of its thermal resistance or R-value—thehigher the R-value, the greater the insulating effectiveness. TheR-value depends on the type of material used in the insulation, itsthickness, and its density and porosity. The R-value of some insulationsalso depends on temperature, aging, and moisture accumulation. Currentmaterials offered for purposes of insulating a structure includeinsulation having vacuum cavities or ‘dead’ air space, such asimpregnated foams, which achieve a high R-value as compared to standardinsulation materials. However, these products will eventually lose theirvacuum (and thereby their effectiveness), and tend to be too expensiveto use as building materials for residential structures, finding moresuitable applications in doors and refrigeration units.

In developing the disclosed technology, it was imperative toaggressively deal with all three methods of heat transfer, each of whichpresent challenges to the fabrication of an economical, energy efficientresidential or commercial structure. In particular, the energyefficiency of the disclosed technology maximizes the afore-describedprinciple that heat cannot be transferred by conduction or convectionthrough a vacuum, overcomes the challenges in creating and maintainingsuch a vacuum, and further mitigates heat transfer by radiation.Structures manufactured using the disclosed technology and the methodsherein described are both economical and resist the forces of naturaldisasters such as hurricanes, tornados and wildfires.

GENERAL DESCRIPTION

The disclosed technology provides affordable, energy efficient, durablebuilding structures and components thereof, and methods of constructingthe same. As herein described, the present invention includes one ormore modules, each module having a vacuous chamber substantially void ofstructural elements, materials and gaseous molecules which wouldotherwise transfer heat energy. This vacuous chamber is provided in theceiling and at least a portion of the walls of a structure, therebymitigating heat loss through conduction and convection.

Acknowledging that the vacuum in the chamber will present significantstress on the walls of the module, and that walls of the modules willlikely be exposed to stress from external high atmospheric pressures andnatural weather phenomenon, external bracing is provided to support themodules and the integrity of the chambers, while not interfering withthe chamber's highly effective resistance to heat flow. Further, modulesdamaged beyond repair by storms, falling trees, etc., may be easilyreplaced in structures of the disclosed technology.

Creating and maintaining a vacuum on a small scale is fairly simple, asdemonstrated in thermos bottles, and various commercially availableinsulation panels commonly used in freezers and residential entrancedoors. Creating and maintaining a vacuum on a larger scale presents asignificant challenge. The net volume of a vacuum chamber needed toeffect proper insulation of an 1,800 ft² residential structure isestimated at or greater than 2,400 ft³. Further, over time there will beeventual loss or degradation of the vacuum in the vacuum chamber, andthere is always a potential for leaks in the chambers. Commerciallyavailable vacuum pumps suitable to create and maintain the vacuum in thelarge vacuous chambers of the modules of the disclosed technology areexpensive, and require significant energy to operate. Therefore, thedisclosed technology further provides a novel apparatus for economicallycreating and maintaining a vacuum within the vacuous chambers of thestructural module, requiring minimum energy to operate.

As stated above, no medium, such as air or water, is needed for theradiation (e.g., from the sun) to travel and transfer heat energy. Tominimize the effect of thermal radiation, exterior elements of thedisclosed technology may be coated with reflective material. Further, aroof structure made from material or covered in a coating designed toreflect radiant heat may be affixed to the modules of the disclosedtechnology. It is also believed that the distance between the walls ofthe vacuum chamber have some effect upon the amount of heat energy thatis transferred via radiation; separating the internal wall of a modulefrom the external wall by at least 12 inches may significantly reduceremnants of thermal radiation.

In certain embodiments, the module chamber is free from structuralelements, but no vacuum is created in the chamber. Preliminary testingreveals that such modules provide a standard insulation R value of about34.

The disclosed technology provides a module useful in constructing anenergy efficient, durable building structure. The module includes anexterior wall, an interior wall and side walls, joined to form avacuous, sealed chamber substantially void of structural elements,materials and gaseous molecules. One or more ribs are affixed to orformed integral with an exterior surface of the exterior wall of themodule, extending the width of the module. A vacuum apparatus may beincorporated in communication with the vacuous, sealed chamber, forcreating and maintaining a vacuum within the module.

In embodiments as hereinafter described, the module may be arc-shaped toincrease the strength of the module and reinforce the exterior wall andthe interior wall against the stresses created by an internal vacuum. Inthese and other embodiments, the module may be formed from a pair ofmodule segments, each module segment being semi-arc shaped, and havingan independent vacuous, sealed chamber.

The disclosed technology further provides an inexpensive, replaceablevacuum apparatus for creating and maintaining a vacuum within a vacuous,sealed chamber of a module useful in constructing an energy efficient,durable building structure, wherein the module includes an exteriorwall, an interior wall and side walls, joined to form the vacuous,sealed chamber. The vacuum apparatus may include a pair of tubes incommunication with the vacuous, sealed chamber. In some embodiments, ashereinafter described, each tube is in liquid communication with theother tube at one end, and with the vacuous, sealed chamber at the otherend. As liquid is pumped into one tube, air is released to theenvironment from that tube, and air is drawn from the vacuous, sealedchamber in the other tube; as the flow of liquid among the tubes isreversed, the flow of air is reversed as well. Systems using thisdisclosed technology are intended to achieve an atmospheric pressurewithin the vacuous, sealed chamber, of between 8-25 inHg, or 10-15 inHg.

The disclosed technology further provides a method of controlling heattransfer within a structure, by providing at least one module as theceiling and at least a portion of the walls of the structure, the modulehaving an exterior wall, an interior wall and side walls, joined to forma vacuous, sealed chamber substantially void of structural elements Oneor more ribs are affixed to or formed integral with an exterior surfaceof the exterior wall. Each module is coupled with a vacuum apparatus incommunication with the vacuous, sealed chamber, for creating andmaintaining a vacuum within the module. The method further includesoperating the vacuum apparatus to draw air out of the vacuous, sealedchamber, until the chamber has an atmospheric pressure of between 8-25inHg, or 10-15 inHg. In embodiments of this technology, the methodfurther includes monitoring the atmospheric pressure within the vacuous,sealed chamber, and further operating the vacuum apparatus when theatmospheric pressure is above a pre-defined level.

FIGURES

FIG. 1A is a peripheral view of an embodiment of the modules of thedisclosed technology;

FIG. 1B is a peripheral view of another embodiment of the modules of thedisclosed technology, with a side wall removed;

FIG. 1C is a side of an embodiment of internal bracing within a moduleof the disclosed technology;

FIG. 2 is a peripheral view of an embodiment of module segments of thedisclosed technology, conjoined to form a module;

FIG. 3 is a peripheral view of an embodiment of conjoined modules of thedisclosed technology;

FIG. 4 is a peripheral view of an embodiment of a structure, having amodule and an end wall of the disclosed technology;

FIG. 5A is a schematic view of an embodiment of a vacuum apparatus ofthe disclosed technology;

FIG. 5B is a peripheral view of the vacuum apparatus of FIG. 5Ainstalled on an embodiment of the module of the disclosed technology;

FIG. 6A is a peripheral view of an embodiment of a module of thedisclosed technology, having a window;

FIG. 6B is a peripheral view of an embodiment of a module of thedisclosed technology, having a door and a foyer area;

FIG. 7A is a peripheral view of an embodiment of a replaceable roofingsystem useful with the modules of the disclosed technology;

FIG. 7B is a closer view of portions of the roofing system of FIG. 7A;

FIG. 7C is a view of an embodiment of an embodiment of a machinedbracket of the roofing system of the disclosed technology;

FIG. 7D is a side view of the ends of an embodiment of the roofing slatsof the roofing system of the disclosed technology;

FIG. 7E is an exploded view of the installment of a roofing slat on abar of a roofing system of the disclosed technology;

FIG. 8A is aside view of an embodiment of the module of the disclosedtechnology installed with raised flooring;

FIG. 8B is a side view of an embodiment of the module of the disclosedtechnology installed on a flat surface;

FIG. 8C is a peripheral view of an embodiment of floor support walls ofthe disclosed technology;

FIG. 8D is another view of the embodiment of floor support walls shownin FIG. 8C;

FIG. 9A is a side view of an embodiment of a module of the disclosedtechnology secured to the ground by means of earth spikes;

FIG. 9B is a side view of an embodiment of a module of the disclosedtechnology supported by end support walls and having a trussed flooring,secured to the ground by means of earth spikes;

FIG. 9C is a side view of an embodiment of earth spikes suitable for usein securing the modules of the disclosed technology to the ground;

FIG. 10A is a side view of an embodiment of a module of the disclosedtechnology supported by floor support walls and having a trussedflooring, installed in trenches;

FIG. 10B is a partial view of the floor support walls of FIG. 10A asinstalled in the trenches; and

FIG. 11 is a peripheral view of an embodiment of modular flooringassembly of the disclosed technology.

DETAILED DESCRIPTION

Embodiments of the disclosed technology provide affordable, energyefficient, durable building structures 200 and components thereof, andfurther methods of construction of structures including the buildingstructures of the disclosed technology or components thereof.

Generally, the structures of the disclosed technology include one ormore modules 1, an embodiment of which is shown in FIGS. 1A, 1B, 2-4,5B, 6A, 6B, 8A, 8B, 9A, 9B, and 10A. Each module has at least onevacuous, sealed chamber 10 substantially void of structural elements,materials and gaseous molecules. The modules may be arc-shaped toincrease the strength of the structure and reinforce the walls againstthe stresses created by the internal vacuum. When conjoined ashereinafter described, the modules form the building structure 200. Thechamber 10 is herein described as a vacuous, sealed chamber, by whichvacuum the chamber achieves a very high R value; however, in someembodiments the chamber are void of structural elements, but are notsupplied with a vacuum, which preliminary testing shows can achieve astandard insulation R value. In larger chambers, structural elements maybe provided to support the integrity thereof, as herein described. Thedisclosed technology is not intended to limit the embodiments of thechamber to one in which a vacuum has been applied or which issubstantially void of structural elements, but rather is intended toalso cover embodiments with chambers to which a vacuum has not beenapplied, or includes structural elements. Embodiments of the modules ofthe disclosed technology may have a length of between 8-14 ft., and awidth of at least 12 ft., or between about 24-40 ft.

As shown in FIG. 2, in some embodiments the modules may besemi-arc-shaped forming module segments 1A, so that when the segmentsare conjoined by bolting or other means as hereinafter described, theyform the module 1, having two chambers 10.

Further, as shown in FIG. 3, a plurality of modules 1 or module segmentsmay be conjoined by bolting or other means, to form structures ofvarying lengths. The design of these modules and module segments providea method of construction which enables the construction of a large sizestructure, while keeping the transportation of the structure (by itscomponents, to a provided site for assembly) practical.

Each module (or module segment) has an exterior wall 11 and an interiorwall 12. The exterior and interior walls are defined by an outer surfaceand an inner surface, wherein the inner surfaces of the walls form thechamber 10. In some embodiments, such as shown in FIGS. 1A, 1B, 2-4, 5B,6A, 6B, 8A, 8B, 9A, 9B, and 10A, the exterior wall and the interior wallare formed in corresponding arc shapes, wherein the degree of curvatureof each of the interior wall 11 and the exterior wall 12 are the same.One or more of the sides of the module or module segments are sealedwith a correspondingly shaped side wall 14 traversing the width of themodule as shown in FIG. 1A, which with the exterior and interior wallsform the chamber 10. Further, each of the ends of the exterior wall andthe interior wall of the module or the module segment may be affixed toa rectangular base 13, extending the length of each side of the module,thereby providing uniform depth along the width of the chamber. Thedepth of the chamber (the space between the exterior wall and theinterior wall) plays a critical role in the net thermal resistance or Rvalue of the module. In arc shaped and segmented embodiments, the depthof the chamber may be consistent along the width thereof, between, forexample, 6″-24″, or 12″-18″, although for larger sized modules the depthof the vacuous chamber may be greater. In an embodiment, the depth of amodule is 12″, and the vacuum in the chamber (established as hereinafterdescribed) has an atmospheric pressure of between 8-25 inHg, or 10-15inHg; theoretically it is believed that in such an embodiment an R valueof up to 300 can be achieved. Increasing the depth of the module chamberand/or the pressure therewithin increases the R value of the chamber.

In the exemplary embodiment shown in FIGS. 1A, 8A, 8B, 9A, 9B and 10A,no materials or structural elements are present within the chamber. Toensure physical integrity of the chambers when substantially void of gasmolecules, one or more bracing elements, such as ribs 15, may be affixedto or formed integral with the exterior surface of the exterior wall ofthe module. At the sides of the module, the ribs 15 may be formedintegral with, and extend from the side walls 14. As herein discussed,bracing the modules and their vacuous chambers on the exterior of themodule, rather than within the chamber, eliminates thermal transferringmaterials within the chamber, and significantly increases the R-value ofthe modules. If internal bracing is required to maintain the structuralintegrity of the modules and the vacuum chamber (e.g., in largermodules, or where the modules are constructed from weaker materials),internal reinforcement ribs 15C may be provided within the vacuumchamber, as shown in FIG. 1B. The design of these internal reinforcementribs may have cutouts 15D, as shown, to minimize heat transfer.

Each of the ribs 15 may extend the width of the arced exterior surfaceof the exterior wall. As shown for example in FIGS. 2, 3, 4, four ribsmay be equidistantly position along the length of a module segment ormodule; more ribs may be necessary for larger modules. These ribs mayhave an architectural design, or may as shown in FIGS. 2, 3 and 4, mayhave a plurality of slots or cutouts 15A, which mitigate the transfer ofheat by means of conduction, and/or facilitate attaching a roof (asshown in FIGS. 7A-7E, and hereinafter described), and further ashereinafter described may provide a means to bolt together modules toincrease the length of the structure.

In some embodiments the outer surface of the exterior walls of themodules or module segments and the ribs may be coated with reflectivematerials to reflect solar rays and mitigate radiant heat transfer.

Structures constructed from modules or module segments as hereinabovedescribed may include a plurality of modules, affixed one-to-anotheralong their sides, as shown in FIG. 3, thereby providing flexibility instructural size. A low thermal conductive gasket material 21 may beplaced between conjoined modules, to prevent air seepage and reduce thethermal conductive properties of the sides of the modules.

As shown in FIG. 4, structures 200 of the disclosed technology may alsoinclude one or more end walls 40 affixed to a side of an end module 1(or module formed from module segments). The end walls may have auniform thickness, with a chamber between an exterior wall and aninterior wall. In this embodiment, and to mitigate heat transfer, theend walls are reinforced by external bracing. Alternatively, standardinsulation may be positioned within the interior and exterior walls ofthe end walls, allowing bracing between the interior and exterior wallsto reinforce the structure. In either embodiment, foam insulation or lowthermal conductive gasket material may be installed between the adjacentsurfaces of the end walls and the corresponding module, to minimizethermal conduction between the components.

As shown in FIGS. 6A and 6B, the modules (or conjoined module segments)can further accommodate windows 201, doors 202, and a foyer 202A, eachof which may be fabricated between the external reinforcement ribs 15,and extending through the chamber 10, while maintaining the integrity ofthe sealed chamber.

In an embodiment, any or all of the modules, bracing elements, and sidewalls of the disclosed technology, and/or components thereof, areconstructed from rolled or step-broke steel, including carbon steel,which while a high thermal conductor is strong, fireproof,non-permeable, easy to fabricate, relativity inexpensive and able tomaintain the vacuum within the vacuous chamber over a long period oftime. Other durable materials may also be suitable for use in theseelements of the disclosed technology. Robotic straight seam welding canbe used to increase quality and dramatically reduce the cost ofconstruction of modules or module segments, walls and bracing elementsof the disclosed technology.

An exemplary structure includes a plurality of modules 1, each modulehaving a width of less than 40 feet and a length of 8 to 14 feet, withan internal height of 8 feet; this height can be extended either byincreasing the internal height of the module, or by walls installedbelow the module, as hereinafter described. These modules and otherstructural components of the disclosed technology may be fabricated at aremote fabrication facility and then transported to the constructionsite. Manufacturers of pre-fabricated structural components of thedisclosed technology may want to be mindful of state regulationsregarding load width/height/length.

At the construction site, the structures may be assembled by conjoiningmodules (or module segments) along their sides as shown in FIG. 3, bybolting their external ribs together, thereby retaining the structuralintegrity and functionality of the chambers 10. When using modulesegments, the same may be conjoined to form modules by bolting anendplate from a first module segment to the corresponding endplate ofthe second module segment, to form a module as shown in FIG. 2.

In an exemplary embodiment, three modules are conjoined as hereinprovided, each module having dimensions of 35⅓ ft.×17 ft., to in theaggregate make a structure of 1,800 ft². For an 1,800 ft² structure, itis estimated that over 2,400 ft³ of vacuous space will be required toachieve desired insulation, although the climate of the intended use maybe considered in determining the vacuous space required to achieve therequisite R value based upon the requirements of the local climate. Thecubic foot volume of a vacuous chamber having a 12-inch depth wouldlikely provide over 2,400 ft³ over all modules.

Structures constructed from the disclosed technology may also include afloor 203. As shown in FIGS. 8A, 9B, 10A, and 11, the floor may includea plurality of trusses 203A, secured to floor support walls 204 to whichthe trusses are bolted or otherwise secured. As shown in FIG. 8C, thefloor support walls may have angle iron 203C welded or otherwise securedtherein to support and secure alignment of the trusses. Plywood or othersuitable flooring material 203D may then be affixed to the tops of thetrusses, as shown in FIG. 11. The trusses may be made from any suitablematerials, including for example wood or steel. By this configuration,forces created by the vacuum in the modules 10, if any, which tend topull the bases of the vacuum chamber together are mitigated. Aninsulating gasket may be positioned between the floor or the floorsupport walls, the base of the modules and/or any the end walls 40.

Further, the floor support walls 204 may be made at any reasonableheight above or below ground. In some embodiments, as shown in FIG. 8Dthese walls 204 have a base 204A wider than the width of the wall 204.Cavities within the floor support walls may include standard insulation,or may be insulated by a vacuum within a vacuous cavity, using theherein-described technology. In an embodiment, as shown in FIGS. 10A and10B, the base 204A sets upon and is bolted to a foundation 300. In someembodiments, such as the embodiment of FIGS. 8A, 9B, and 10A, the use offloor support walls to raise the floor of the structure yields a higherinterior ceiling within the structure, and provides a crawl-space belowthe floor suitable for utilities, equipment and storage.

As shown in FIGS. 10A and 10B, in an embodiment the floor support wallsmay be installed in trenches. The depth of the trenches may bedetermined based upon the soil quality at the site; a trench of at least3 feet is recommended. Reinforcing rods 302 may be driven into the baseof each trench, and concrete is poured into the trenches. All threadrods 303 may be positioned and cast into the concrete, sized andconfigured to align with corresponding apertures of the base 204A.Finally, once the floor support walls are positioned, the trenches maybe backfilled using tamped soil, concrete or other suitable materials.

In an alternative configuration, as shown in FIGS. 9A and 9B, a largeearth spike 310 may be coupled with the modules or base of the floorsupport walls to secure the structure to the ground. In thisconfiguration, the structure of the disclosed technology may beconstructed in remote locations (inaccessible to drench diggingequipment, for example), and/or easily moved from one site to another.The spike may be made from galvanized steel, for example, or othersuitable material. To install the spikes, a hole is augured into theground, and the spike may then be hydraulically pushed into the ground.As shown in FIG. 9C, the spike 310 has a top plate 311, the position ofwhich may be adjusted (by adjusting the position of one or more cornersof the top plate 311 relative to the bottom plate 312), to ensure thestructure is supported horizontal with the horizon. In this embodiment,corners of the module(s) or module segments are then secured to the topplate 311 of the spike, by welding or otherwise.

These floor and base embodiments may be partially or whollypre-fabricated, an example of which is shown in FIG. 11. In thisembodiment, a pre-fabricated base inclusive of any of the floor 203,floor support walls 204, trusses 203A, and/or flooring material 203D maybe supplied with each module (or set of module segments), conjoined withthe module at the construction site. In some further embodiments,accommodations are made on the bottom side of the floor and base tosupport utility wiring and other piping or structure, thereby furtherdecreasing the cost and time of assembly at the construction site.

In yet another embodiment, as shown in FIGS. 8B and 9A, the floor 203may be a concrete pad 50 upon which the assembled structure ispositioned; as hereinabove described, floor support walls may provideadditional height to the structure, with or without raised flooring.

In yet another embodiment, the modules may be affixed to a foundationwhich is anchored to the earth, such as a plurality of prefabricatedwide and hollow steel walls of any height. The foundation may be a footwider than the dimensions of the modules or the structure including aplurality of modules. The cavities of the walls forming the foundationcan be filled with soil or other types of heavy insulation. Concretewalls may be bolted to the foundation anchored to the earth to provide aplatform to which the structure of the disclosed technology may anchor.In this and other embodiments, the foundation may provide a vacuousspace sufficient to accommodate a basement.

As shown in FIG. 5A, embodiments of the disclosed technology may furtherinclude a vacuum apparatus 100 for creating and maintaining a vacuumwithin a module 1 or a module segment 1A. The apparatus may bepositioned between two of the external ribs of each module (see, e.g.,FIG. 5B). By having a vacuum apparatus for each module, no plumbingbetween modules would be required. In other embodiments, the modules maybe connected with plumbing, connecting one or more vacuum chambers so asingle vacuum pump could be used to create and maintain the vacuumlevels in some or all of the modules of a structure. This plumbing maybe designed so that each module may still remain separate from theothers, which would permit control of the R values of each moduleindependently of the others.

In one embodiment, as shown in FIG. 5A, an inexpensive, replaceable,vacuum apparatus 100 includes two tubes 101, 102. The tubes may have aninner diameter of 6-12″, wherein the diameter of the tubes control therate at which the vacuum is created. Further, the tubes may be 5-8 ft.long, and in some embodiments (not shown) may have a curvaturecorresponding with the curvature of the exterior walls of thecorresponding module. The tubes may be made from schedule 80 polyvinylchloride (PVC) or steel, or other suitable materials.

As shown in FIG. 5B, the top of each tube of the vacuum apparatus has atop inlet 101A, 102A, each in sealed communication with the chamber 10,and a top outlet 102A, 102B, which emits air to the environment. Each ofthe inlet/outlet pairs are controlled by a shutoff valve 101C, 102C,which valve directs whether air is drawn by the respective tube from thevacuum chamber or emitted to the environment. The valves may beelectrically operated, and are normally closed until energized. As shownin FIG. 5B, the tubes are mounted in a vertical or angular position tothe module, such as for example the exterior surface, between two ribs.

Likewise, the base of each tube has a base outlet 101D, 102D, and a baseinlet, 101E, 102E, each pair of which are also controlled by a shutoffvalve 101F, 102F, the valves being normally closed until energized. Afirst outlet of each tube 101D, 102D is connected to the correspondinginlet 102E, 101E of the other tube, in each case through a liquidtransfer pump 110. One way check valves may be positioned throughout thesystem to prevent any vacuum from escaping from the vacuum chamber, orliquid to pass in an unintended direction. The shutoff valves controlthe flow of liquid within the system, and permit air to escape from thetubes being filled and draw the vacuum from the chamber at the end ofeach stroke.

The liquid transfer pump 110 of the vacuum apparatus may be a singlephase 120 v system, having a flow rate of at least 4,000 gallons perhour (gph), requiring less than 8 amps of power. With this low energyrequirement, the pump can be powered by wind or solar power.

As shown in FIG. 5A, in operation, the first tube 101 is filled with theintended liquid (e.g., brake fluid, or other or other high-boiling pointliquid), and the second tube 102 is partially filled with the sameliquid. The inlet valve 101A of the first tube is set to draw air fromthe vacuum chamber, and the outlet valve of the second tube is set todeliver air to the environment. The liquid is drawn from the first tubethrough the base outlet 101D by means of the liquid transfer pump, anddelivered to the second tube at its base inlet 102E, which creates avacuum at the top of the first tube, and by this configuration pullsgasses (air) from the vacuum chamber 10 of the module into the firsttube, and expels air into the environment from the second tube. When thesecond tube is full of liquid, the electrically operated valves reverse,so that the inlet of the second tube is set to draw air from the vacuumchamber, and the inlet of the first tube is set to deliver air to theenvironment. The liquid is drawn from the base outlet 102D of the secondtube by means of the liquid transfer pump, and delivered to the firsttube at its inlet 102E, which creates a vacuum at the top of the secondtube, and by this configuration pulls gasses (air) from the vacuumchamber 10 of the module into the second tube, and expels air into theenvironment from the first tube, until the first tube is full of liquid.The cycle is automatically repeated until the proper vacuum has beenachieved within the vacuum chamber of the module.

As shown in FIG. 5D, when the apparatus has achieved the desired vacuumwithin the chamber of the modules, the shutoff valves 101C, 102C, 101Fand 102F, are all de-energized, preventing any vacuum from escaping themodule.

The vacuum apparatus may include an electrical controller or logiccomputer program to control the cycles and overall operation of thevacuum apparatus The vacuum apparatus may also include a pressure sensorwithin the module which can communicate a pressure level within themodule to the electrical controller to stop operation of the system andde-energize the shutoff valves when the pressure within the vacuumchamber is above a predetermined vacuum level; and to start operation ofthe system and energize the shutoff valves when the vacuum falls below apredetermined value. By this configuration, the controller can detectany air leaks within a module by a rapid change in pressure therewithin.

In other embodiments, the vacuum apparatus may be a hydraulic plungersystem coupled with a hydraulic pump or cable winch.

In larger structures a low pressure high volume impeller fan (e.g., fansused in cyclone dust collection systems) can be used to initiallyrapidly remove a large portion of the air from the vacuum chamber whencoupled with the chamber; thereafter a vacuum apparatus as hereinabovedescribed may be positioned on the vacuum chamber to complete theevacuation process, and maintain the vacuum within the chamber.Commercially available vacuum pumps, although expensive, can be usedwith one or more modules of the disclosed technology.

Acknowledging that holes could appear in a wall of the modules, it isimportant that this this hole can be easily accessed for repair. While ahole would be fully accessible when a roof is not provided, as shown inFIGS. 7A, 7B, 7C, 7D and 7E, a series of roofing slats may be positionedamong the ribs of the module. In this embodiment, and as shown in FIGS.7A, 7B and 7E, a series of flat bars 400 to support the roofing slatsmay be welded to the top of the ribs 15. Each flat bar supports aplurality of roofing slats 401, which collectively form the roof. Theslats may comprise a material resistant to radiant heat from the sun.These slats can be attached to the flat bars 400 using bolts, althoughover time bolts can become corroded and become difficult to remove.Further, it may be difficult to align the bolts with the holes in theflat bar after the slats 401 are removed to conduct a repair. Tomitigate this problem, machined brackets 402 may be bolted to the roofforming slats 401, distanced so that they may receive (in the machinedpart thereof) and hang on the flat bars 400, removably supporting theroof slats. A removable stop bar 303 may be positioned between the ribs,to contain upward movement of the roofing slats; once this stop bar isremoved, the slat bars may likewise be removed to expose a hole or areaneeding repair, and then repositioned on the flat bars. Using thismethod, any point on the outer surface of the module (where, forexample, a leek has developed) can be accessed by removing the proximateone or more slats, without removing a large section of the roof.Further, by this design individual roofing slats which have deterioratedover time can be easily removed and replaced.

Tests conducted on current technologies as compared to anrectangular-shaped module having a length of 36″, a width of 24″, and adepth of 12″, void of structural elements within the vacuous chamber ofthe module. The material/structure tested was positioned between a hotroom and a test room. The hot room was heated to a temperature of 84°F., and the test room was cooled to a temperature of 60° F. In the testthe amount of time it took for the rooms to achieve the same temperaturewas measured, which revealed the following:

Material/structure Time R Value 6″ polystyrene insulation 6 hrs. 30Module, no vacuum applied 7 hrs. 34 Module, 5 inHg vacuum applied 9.5hrs. 46 Module, 10 inHg vacuum applied 14 hrs. 71 Module, 15 inHg vacuumapplied 15.5 hrs. 78 Module, 20 inHg vacuum applied 20 hrs. 100

The invention claimed is:
 1. A module useful in constructing an energyefficient, durable building structure, the module comprising: a. anexterior wall, an interior wall and side walls, joined to form a firstvacuous, sealed chamber substantially void of structural elements,materials and gaseous molecules; b. one or more ribs affixed to orformed integral with an exterior surface of the exterior wall; and c. avacuum apparatus in communication with the vacuous, sealed chamber, forcreating and maintaining a vacuum within the module.
 2. The module ofclaim 1, wherein the module is arc-shaped to increase the strength ofthe module and reinforce the exterior wall and the interior wall againstthe stresses created by an internal vacuum, and wherein the degree ofcurvature of the interior wall is the same as the degree of curvature ofthe exterior wall.
 3. The module of claim 1, wherein the modulecomprises a pair of module segments, each module segment being semi-arcshaped, and having a vacuous, sealed chamber so that when conjoined toform the module, the module also has a second vacuous, sealed chamber.4. The module of claim 1, wherein each of the ends of the exterior walland the interior wall are affixed to a rectangular base.
 5. The moduleof claim 1, wherein the depth of the chamber is at least 12 inches. 6.The module of claim 1, wherein the ribs extend the width of the module.7. The module of claim 1, further comprising a roofing system includinga plurality of flat bars secured to and between the ribs, and aplurality of roof slats, each roof slat having a plurality of machinedbrackets affixed along the length thereof, to receive and removablysecure the roof slats to the flat bars.
 8. The module of claim 1,wherein the module has a length of between about 8-14 ft., and a widthof between about 24-40 ft.